Multifunctional collimator for contact image sensors

ABSTRACT

Disclosed is a cost-effective method to fabricate a multifunctional collimator structure for contact image sensors to filter ambient infrared light to reduce noises. In one embodiment, an optical collimator, includes: a dielectric layer; a substrate; a plurality of via holes; and a conductive layer, wherein the dielectric layer is formed over the substrate, wherein the plurality of via holes are configured as an array along a lateral direction of a first surface of the dielectric layer, wherein each of the plurality of via holes extends through the dielectric layer and the substrate from the first surface of the dielectric layer to a second surface of the substrate in a vertical direction, and wherein the conductive layer is formed over at least one of the following: the first surface of the first dielectric layer and a portion of sidewalls of each of the plurality of via holes, and wherein the conductive layer is configured so as to allow the optical collimator to filter light in a range of wavelengths.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/656,290, filed Oct. 17, 2019, which is incorporated by referenceherein in its entirety.

BACKGROUND

In order to prevent noises from ambient infrared (IR) sources, a contactimage sensor (CIS), e.g., a finger print sensor, typically employs aglass filter. The glass filter in such application is typically thick(e.g., 400-500 micrometers) so as to provide efficient filtering ofambient IR noises especially at high incident angles (>15 degree). Thisresults in a bulky assembly and can increase the cost. There exists aneed to develop a cost-effective method to filter ambient infrared lightto reduce noises in contact image sensors.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that various features are not necessarily drawn to scale. In fact,the dimensions and geometries of the various features may be arbitrarilyincreased or reduced for clarity of illustration.

FIG. 1 illustrates a flow chart of an exemplary method for forming asemiconductor device, in accordance with some embodiments of the presentdisclosure.

FIGS. 2A, 2B, 2C, 2D, 2E, 2F, 2G, and 2H, illustrate cross-sectionalviews of an exemplary semiconductor device with a collimator duringvarious fabrication stages, made by the method of FIG. 1 , in accordancewith some embodiments of the present disclosure.

FIG. 3 illustrates an exemplary cross-sectional views of a semiconductordevice with a collimator, in accordance with some embodiments of thepresent disclosure.

FIG. 4 illustrates exemplary cross-sectional views of sidewall profilesof etched openings in a collimator structure, in accordance with someembodiments of the present disclosure.

FIG. 5A illustrates an exemplary top view of a semiconductor device witha collimator, in accordance with some embodiments of the presentdisclosure.

FIG. 5B illustrates an exemplary top view of a semiconductor device witha collimator, in accordance with some embodiments of the presentdisclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following disclosure describes various exemplary embodiments forimplementing different features of the subject matter. Specific examplesof components and arrangements are described below to simplify thepresent disclosure. These are, of course, merely examples and are notintended to be limiting. For example, it will be understood that when anelement is referred to as being “connected to” or “coupled to” anotherelement, it may be directly connected to or coupled to the otherelement, or one or more intervening elements may be present.

A thick IR glass can be used to filter undesired ambient noises for aCIS sensor. This design results in a bulky structure and increases acost of such CIS sensor. This disclosure presents various embodiments ofa method for integrating a filter function to a collimator for contactimage sensors to simultaneously align incident light and filter ambientnoises with a compact design and low cost.

FIG. 1 illustrates a flowchart of a method 100 to form a multifunctionalcollimator structure on a semiconductor device, in accordance with someembodiments of the present disclosure. It is noted that the method 100is merely an example, and is not intended to limit the presentdisclosure. Accordingly, it is understood that additional operations maybe provided before, during, and after the method 100 of FIG. 1 , andthat some other operations may only be briefly described herein. In someembodiments, operations of the method 100 may be associated withcross-sectional views of a semiconductor device at various fabricationstages as shown in FIGS. 2A, 2B, 2C, 2D, 2E, 2F, 2G, and 2H, 2I,respectively, which will be discussed in further detail below.

Referring now to FIG. 1 , the method 100 starts with operation 102 inwhich a first substrate is provided according to some embodiments. Insome embodiments, the first substrate comprises at least one opticalsensing element. The method 100 continues with operation 104 in which afirst dielectric layer is deposited on the surface of the firstsubstrate according to some embodiments. In some embodiments, the firstdielectric layer comprises silicon oxide for planarization of a CMOSbackend topography and creating a Si to oxide Fu-bond surface. Themethod 100 continues with operation 106 in which a second substrate isbonded over the first dielectric layer on the first substrate accordingto some embodiments. In some embodiments, the second substrate is bondedto the first dielectric layer through a wafer bonding process. In someembodiments, the second substrate is a silicon substrate. The method 100continues with operation 108 in which a second substrate is thinned downaccording to some embodiments. In some embodiments, the thinned secondsubstrate has a thickness of 75 micrometers. The method 100 continueswith operation 110 in which a second dielectric layer is deposited on afirst surface of the second substrate according to some embodiments. Insome embodiments, the second dielectric layer comprises silicon oxide.The method 100 continues with operation 112 in which a photoresist layeris patterned on the second dielectric layer according to someembodiments. In some embodiments, the patterned photoresist layerprovides a pattern of a collimator structure.

The method 100 continues with operation 114 in which a plurality of viaholes through the second dielectric layer and the thinned secondsubstrate is formed according to some embodiments. In some embodiments,the plurality of via holes is formed by etching the second dielectriclayer using the patterned first photoresist layer as a soft maskfollowed by etching the thinned second substrate using the patternedsecond dielectric layer as a hard mask. The method 100 continues withoperation 116 in which at least one conductive feature is formed in thefirst dielectric layer according to some embodiments. In someembodiments, the at least one conductive feature provides an electricalcontact to the at least one sensing element in the first substrate. Themethod 100 continues with operation 118 in which a second photoresistlayer is formed in the plurality of via holes so as to expose a firstsurface of the second dielectric layer and a portion of sidewalls in theplurality of via holes according to some embodiments. In someembodiments, the second photoresist layer is coated and etched so as toexpose a portion of the collimator structure. The method 100 continueswith operation 120 in which at least one conductive layer is depositedaccording to some embodiments. In some embodiments, the at least oneconductive layer each comprises a metal layer. The method 100 continueswith operation 122 in which the sacrificial layer and the at least oneconductive layer in contact with the sacrificial layer are removedaccording to some embodiments. In some embodiments, a chemical etchingprocess is performed so as to remove the sacrificial layer and a portionof the at least one conductive layer that is in direct contact with thesacrificial layer. In some embodiments, the semiconductor with thecollimator structure is then wafer diced to form a plurality of dies. Insome embodiments, each of the plurality of dies is then wafer bonded toa third substrate and wire bonded. In some embodiments, each of theplurality of dies is embedded in a molding and packaged.

As mentioned above, FIGS. 2A-2H illustrate, in a cross-sectional view, aportion of a semiconductor device 200 at various fabrication stages ofthe method 100 of FIG. 1 . The semiconductor device 200 may be includedin an integrated circuit (IC). Also, FIGS. 2A-2H are simplified for abetter understanding of the concepts of the present disclosure. Althoughthe figures illustrate the semiconductor device 200, it is understoodthe IC may comprise a number of other devices such as resistors,capacitors, inductors, fuses, etc., which are not shown in FIGS. 2A-2H,for purposes of clarity of illustration.

FIG. 2A is a cross-sectional view of the semiconductor device 200including a first substrate 202 and a first dielectric layer 204 at oneof the various stages of fabrication corresponding to operations 102 and104 of FIG. 1 , in accordance with some embodiments of the presentdisclosure. In some embodiments, the first substrate 202 comprises atleast one optical sensing element (not shown). In some embodiments, theat least one optical sensing element each is a Contact Image Senor(CIS). In some embodiments, the CIS is an image sensor used in directcontact with the object to be imaged or scanned. In some embodiments,the CIS comprises a plurality of detectors. In some embodiments, theplurality of detectors detects light directed from an object surface. Insome embodiments, the plurality of detectors each comprises one of thefollowing: a Charge Coupled Device (CCD) sensor and a Complementarymetal-oxide semiconductor (CMOS) sensor.

In some embodiments, the first substrate 202 is a silicon substrate.Alternatively, the first substrate 202 may include other elementarysemiconductor material such as, for example, germanium. The firstsubstrate 202 may also include a compound semiconductor such as siliconcarbide, gallium arsenic, indium arsenide, and indium phosphide. Thefirst substrate 202 may include an alloy semiconductor such as silicongermanium, silicon germanium carbide, gallium arsenic phosphide, andgallium indium phosphide. In one embodiment, the first substrate 202includes an epitaxial layer. For example, the first substrate 202 mayhave an epitaxial layer overlying a bulk semiconductor. Furthermore, thefirst substrate 202 may include a semiconductor-on-insulator (SOI)structure. For example, the first substrate 202 may include a buriedoxide (BOX) layer formed by a process such as separation by implantedoxygen (SIMOX) or other suitable technique, such as wafer bonding andgrinding.

In some embodiments, the first substrate 202 also includes variousp-type doped regions and/or n-type doped regions, implemented by aprocess such as ion implantation and/or diffusion. Those doped regionsinclude n-well, p-well, lightly doped region (LDD), heavily doped sourceand drain (S/D), and various channel doping profiles configured to formvarious integrated circuit (IC) devices, such as a CMOS field-effecttransistor (CMOS-FET), imaging sensor, and/or light emitting diode(LED). The first substrate 202 may further include other functionalfeatures such as a resistor or a capacitor formed in and on thesubstrate. The first substrate 202 further includes lateral isolationfeatures provided to separate various devices formed in the firstsubstrate 202, for example shallow trench isolation (STI). The variousdevices in the first substrate 202 further include silicide disposed onS/D, gate and other device features for reduced contact resistance andenhance process compatibility when coupled between devices through localinterconnections.

In some embodiment, at least one conductive feature is included in thefirst substrate 202. In some embodiments, the at least one conductivefeature can be a source, drain or gate electrode. Alternatively, the atleast one conductive feature may be a silicide feature disposed on asource, drain or gate electrode typically from a sintering processintroduced by at least one of the processes including thermal heating,laser irradiation or ion beam mixing. The silicide feature may be formedon polysilicon gate (typically known as “polycide gate”) or by onsource/drain (typically known as “salicide”) by a self-aligned silicidetechnique. In another embodiment, the at least one conductive featuremay include an electrode of a capacitor or one end of a resistor. Inanother embodiment, the at least one conductive feature is a contact tothe CIS sensor in the first substrate 202.

In some embodiments, the first dielectric layer 204 comprises a materialthat is at least one of the following: silicon oxide, a low dielectricconstant (low-k) material, other suitable dielectric material, or acombination thereof. The low-k material may include fluorinated silicaglass (FSG), phosphosilicate glass (PSG), borophosphosilicate glass(BPSG), carbon doped silicon oxide (SiO_(x)C_(y)), Black Diamond®(Applied Materials of Santa Clara, Calif.), Xerogel, Aerogel, amorphousfluorinated carbon, Parylene, BCB (bis-benzocyclobutenes), SiLK (DowChemical, Midland, Mich.), polyimide, and/or other future developedlow-k dielectric materials. In some embodiments, the first dielectriclayer 204 is deposited using plasma enhanced chemical vapor deposition(PECVD) with a silane gas as a precursor gas. In some other embodiments,the first dielectric layer 204 is deposited using a physical vapordeposition (PVD) process.

FIG. 2B is a cross-sectional view of the semiconductor device 200including the first substrate 202, the first dielectric layer 204 and asecond substrate 206 at one of the various stages of fabrication thatcorresponds to operation 106 of FIG. 1 , in accordance with someembodiments of the present disclosure. In some embodiments, the secondsubstrate 206 includes a silicon substrate. Alternatively, the secondsubstrate 206 may include other elementary semiconductor materialaccording to the optical properties of the materials, such as, forexample, germanium. The second substrate 206 may also include a compoundsemiconductor such as silicon carbide, gallium arsenic, indium arsenide,and indium phosphide. The second substrate 206 may include an alloysemiconductor such as silicon germanium, silicon germanium carbide,gallium arsenic phosphide, and gallium indium phosphide. In oneembodiment, the second substrate 206 includes an epitaxial layer. Forexample, the second substrate 206 may have an epitaxial layer overlyinga bulk semiconductor. Furthermore, the second substrate 206 may includea semiconductor-on-insulator (SOI) structure. For example, the secondsubstrate 206 may include a buried oxide (BOX) layer formed by a processsuch as separation by implanted oxygen (SIMOX) or other suitabletechnique, such as wafer bonding and grinding.

In some embodiments, the second substrate 206 is bonded to the firstdielectric layer 204 through a wafer bonding process. In someembodiments, the wafer bonding process is a direct bonding without anyadditional intermediate layers. In some embodiments, the wafer bondingprocess comprises at least one of the following steps: surfacepreprocessing, pre-bonding at room temperature, and annealing atelevated temperatures. In another embodiment, surface activation can beused so as to avoid high temperature annealing.

FIG. 2C is a cross-sectional view of the semiconductor device 200including a second dielectric layer 208 over an thinned second substrate206 at one of the various stages of fabrication that corresponds tooperations 108 and 110 of FIG. 1 , in accordance with some embodimentsof the present disclosure. In some embodiments, the second substrate 206after bonding to the first dielectric layer 204 on the first substrate202 is further thinned down to obtain a desired thickness. In someembodiments, the second substrate 206 is etched by a dry and/or wetetching process. In some embodiments, the etched second substrate 206has a thickness of 75 micrometer. In some embodiments, the seconddielectric layer 208 is deposited on the etched second substrate 206. Insome embodiments, the second dielectric layer 208 comprises a materialthat is least one of the following: silicon oxide, a low dielectricconstant (low-k) material, other suitable dielectric material, or acombination thereof. The low-k material may include fluorinated silicaglass (FSG), phosphosilicate glass (PSG), borophosphosilicate glass(BPSG), carbon doped silicon oxide (SiO_(x)C_(y)), Black Diamond®(Applied Materials of Santa Clara, Calif.), Xerogel, Aerogel, amorphousfluorinated carbon, Parylene, BCB (bis-benzocyclobutenes), SILK (DowChemical, Midland, Mich.), polyimide, and/or other future developedlow-k dielectric materials. In some embodiments, the second dielectriclayer 208 is deposited using plasma enhanced chemical vapor deposition(PECVD) with a silane gas as a precursor gas. In some other embodiments,the second dielectric layer 208 is deposited using a physical depositionprocess, e.g., sputtering and evaporation. In some embodiments, thesecond dielectric layer 208 is deposited using an atomic layerdeposition (ALD) process. In some embodiments, the second dielectriclayer 208 has a thickness of at least 3,000. In some embodiments, thesurface of the second substrate that is not in direct contact with thefirst dielectric layer 204 after etching is further planarized through aChemical-Mechanical Polishing (CMP) process before the deposition of thesecond dielectric layer 208.

FIG. 2D is a cross-sectional view of the semiconductor device 200 inwhich a photoresist layer 210 is patterned on the second dielectriclayer 208 at one of the various stages of fabrication that correspondsto operation 112 of FIG. 1 , in accordance with some embodiments of thepresent disclosure. As described below, the patterned photoresist layer210 is used to mask an etching of the second dielectric layer 208 andthe thinned second substrate 206 to form a plurality of via holes (i.e.,a collimator structure) on top of the first dielectric layer 204 on thefirst substrate 202. Accordingly, in some embodiments, the patternedphotoresist layer 210 is formed after a conventional patterning (e.g.,photolithography) process, to align the collimate structure with the atleast one optical sensing element in the first substrate 202.

In some embodiments, an initial photoresist layer 210 before thepatterning process may include a negative or positive tone photoresistlayer that is patternable in response to a photolithography lightsource. In some alternative embodiments, the initial photoresist layer210 may include an e-beam (electron beam) resist layer (e.g., polymethyl methacrylate, methyl methacrylate, etc.) that is patternable inresponse to an e-beam lithography energy source. In some embodiments,the initial photoresist layer 210 is formed over the second dielectriclayer 208 using a deposition process known in the art such asspin-coating, spray-coating, dip-coating, roller-coating, or the like.The initial photoresist layer 210 is then patterned in a lithographyprocess that may involve various exposure, developing, baking,stripping, etching, and rinsing processes. As a result, the patternedphotoresist layer 210 is formed such that a plurality of openings 212expose at least a portion of the top surface of the second dielectriclayer 208, as shown in FIG. 2D. In some embodiments, the plurality ofopenings 212 in the patterned photoresist layer is circular and has adiameter of 4 micrometers. In some embodiments, the diameters of theplurality of openings are in a range of 1-3 micrometers, and in someembodiments the diameter is 2 micrometers.

FIG. 2E is a cross-sectional view of the semiconductor device 200 inwhich a plurality of via holes is formed in the second dielectric layer208 and the etched second substrate 206, the patterned photoresist layer210 is removed and at least one conductive feature 214 is formed in thefirst dielectric layer 204 at one of the various stages of fabricationthat corresponds to operations 114 and 116 of FIG. 1 , in accordancewith some embodiments of the present disclosure. In some embodiments,the second dielectric layer 208 is first etched so as to transfer thepattern in the patterned photoresist layer 210 with the plurality ofopenings 212 to the second dielectric layer 208. In some embodiments thepatterned second dielectric layer 208 is then further etched so as totransfer the patterns in the second dielectric layer 208 to the thinnedsecond substrate 206. In some embodiments, the etching of the seconddielectric layer 208 and the second substrate 206 is performed by a dryand/or wet etching process.

In some embodiments, the patterned photoresist layer 210 is removedbefore the etching of the second substrate 206. In some embodiments, thepatterned photoresist layer 210 may be removed by one or more chemicalcleaning processes using acetone, 1-Methyl-2-pyrrolidon (NMP), Dimethylsulfoxide (DMSO), or other suitable removing chemicals. In someembodiments, the chemicals used may need to be heated to temperatureshigher than room temperature to effectively dissolve the patternedphotoresist layer 210. The selection of the remover is determined by thetype and chemical structure of the patterned photoresist layer 210, thesecond dielectric layer 208, as well as the second substrate 206 toassure the chemical compatibility of these layers with the chemicalcleaning process. In some embodiments, this cleaning process is thenfollowed by a rinsing process using isopropyl alcohol or the like,followed by rinsing using deionized water. As a result of this process,the plurality of via holes 216, i.e., the collimator structure, areformed through the second dielectric layer 208 and the second substrate206. In some embodiments, the collimator structure comprises a topsurface 216 of the second dielectric layer 208 and sidewalls 220.

In some embodiments, the at least one conductive feature 214 is formedin the first dielectric layer 204 so as to provide an electric contactto the at least one optical sensing element in the first substrate 202.In some embodiments, the conductive feature 214 is formed through aseparate conventional patterning (e.g., photolithography) process, whichmay involve various exposure, developing, backing, stripping, etchingand rinsing processes. In some embodiments, the conductive feature 214is formed by using CVD, PVD, spin-on-coating and/or other suitabletechniques to deposit conductive materials over a separately patternedphotoresist layer, followed by a wet-etching of the photoresist layer.As a result, the at least one conductive feature 214 is formed in thefirst dielectric layer 204.

FIG. 2F is a cross-sectional view of the semiconductor device 200 inwhich a sacrificial layer 222 is formed in the plurality of via holes216 and a portion of the collimator structure is expose at one of thevarious stages of fabrication that corresponds to operation 118 of FIG.1 , in accordance with some embodiments of the present disclosure. Insome embodiments, the sacrificial layer 222 is a photoresist layer whichcan be formed by filling in the collimator structure with photoresists.In some embodiments, the sacrificial layer 222 can be partially removedin a dry etching process with a selectivity that allows a negligibleetching to the second dielectric layer 208 and the second substrate 206.As a result, a portion of the collimator structure from its top surfacecan be exposed. Specifically, the top surface 218 of the seconddielectric layer 208, a portion (220A) of the sidewalls 220 of theplurality of via holes 216 are exposed. In some embodiments, the depthof the exposed portion 220A of the sidewalls 220 is less than thethickness of the second dielectric layer 208. In some other embodiments,the depth of the exposed portion 220A of the sidewall 220 is greaterthan the thickness of the second dielectric layer 208.

FIG. 2G is a cross-sectional view of the semiconductor device 200 inwhich a conductive layer 224 is deposited at one of the various stagesof fabrication that corresponds to operation 120 of FIG. 1 , inaccordance with some embodiments of the present disclosure. In someembodiments, the conductive layer 224 is deposited using a PVD process(e.g., sputtering and evaporation). In some embodiments, the conductivelayer 224 comprises a plurality of conductive layers stacked in alayer-by-layer fashion. In some embodiments, the conductive layer 224 isin direct contact with the top surface 218 and the portion 220A of thesidewalls 220 of the collimator structure. In some embodiments, theconductive layer 224 is also deposited on the surface of the sacrificiallayer 218. In some embodiments, the conductive layer 224 comprises analuminum-copper (AlCu) alloy. In some embodiments, an Al/Cu ratio is ina range of 190 to 210, and in some embodiments, the ratio is 199. Insome embodiments, the Al/Cu ratio is controlled by the composition of atarget. In some other embodiments, the Al/Cu ratio is determinedaccording to deposition rates of two separate targets. In someembodiments, the thickness of the conductive layer 224 on the surface ofthe sacrificial layer 222 and the top surface 218 of the collimatorstructure is 900 nanometers. In some other embodiments, the thickness ofthe conductive layer 224 on the surface of the sacrificial layer 222 andthe top surface 218 of the collimator structure is in a range of 8 to 12micrometers, and in some embodiments the thickness is 10 micrometers. Insome embodiments, the thickness of the conductive layer 224 on thesidewalls 220A of the collimator structure is different from that on thetop surface 218 due to a difference in deposition rate on differentsurfaces. In some other embodiments, a conformal coating of theconductive layer 224 can be used to obtain a comparable thickness ofconductive layers on the top surface 218 and the sidewalls 220A. In someembodiments, other metallic materials and alloys can be used in theconductive layer 224 according to the desired operation conditions forthe CIS sensor (e.g., a wavelength range to be filtered by thecollimator structure) and optical properties of materials, which are allwithin the scope of this invention.

FIG. 2H is a cross-sectional view of the semiconductor device 200 inwhich the collimator structure is formed at one of the various stages offabrication that corresponds to operation 122 of FIG. 1 , in accordancewith some embodiments of the present disclosure. In some embodiments,the sacrificial layer 222 is removed by one or more chemical cleaningprocesses using suitable chemicals. For example, when the sacrificiallayer 222 is a photoresist layer, the sacrificial layer 222 can beremoved by acetone, 1-Methyl-2-pyrrolidon (NMP), and Dimethyl sulfoxide(DMSO). In some embodiments, the chemicals used may need to be heated totemperatures higher than room temperature to effectively dissolve thesacrificial layer 222. The selection of the remover is determined by thetype and chemical structure of the conductive layer 224, the seconddielectric layer 208, as well as the second substrate 206 to assure thechemical compatibility of these layers with the chemical cleaningprocess. In some embodiments, this cleaning process is then followed bya rinsing process using isopropyl alcohol or the like, followed byrinsing using deionized water. As a result, the conductive layer 224that are in direct contact with the sacrificial layer 222 is removed.

In some embodiments, the collimator structure narrows incident light andallow the incident light to be aligned in a specific direction when thelight arrives at the at least one optical sensing element in the firstsubstrate. Furthermore, the collimator structure with the conductivelayer 224 further allows to filter undesired ambient noises and preventthese noises from reaching the at least one optical sensing element.Therefore, the conductive-layer-coated collimator structure in thepresent disclosure provides multiple functions allowing the use ofregular glass during packaging and thus reducing the cost, and furtherallowing the use of CIS devices in space-limited applications.

FIG. 3 illustrates an exemplary cross-sectional view of a semiconductordevice 300 with a collimator structure, in accordance with someembodiments of the present disclosure. In the illustrated embodiment,the collimator structure is fabricated according to the method 100described in FIG. 1 . Specifically, the device 300 comprises a firstsubstrate 202, a first semiconductor layer 204, a plurality of via holesin a second substrate 206 and a second dielectric layer 208, and aconductive layer 224. In the illustrated embodiments, the conductivelayer 224 is deposited on a first surface 218 of the second dielectriclayer 208 and also on a portion of sidewalls 220A of the plurality ofvia holes.

In some embodiments, the patterned second dielectric layer 208 has athickness 302 in a range of 0.8 to 1.2 micrometers, and in someembodiments is 1.0 micrometers. In some embodiments, the patternedsecond substrate 206 has a thickness 304 in a range of 4 to 8micrometers, and in some embodiments is 6 micrometers. In someembodiments, the patterned second dielectric layer 208 has a thickness306 in a range of 0.8 to 1.2 micrometers, and in some embodiments is 1.0micrometers.

In some embodiments, a pitch size 308 is in a range of 0.5 to 1.0micrometers, and in some embodiments is 0.8 micrometers. In someembodiments, a diameter of an opening 216 before the deposition of theconductive layer 224 is in a range of 0.03 to 0.08 micrometers, and insome embodiments is 0.05 micrometers. In some embodiments, a firstthickness 312 of the conductive layer 224 in the y direction on thefirst surface 208 is in a range of 180 to 220 nanometers, and in someembodiments is 200 nanometers. In some embodiments, a second thickness314 of the conductive layer in the x direction on the sidewalls 220A ofthe collimator structure is in a range of 15 to 25 nanometers, and insome embodiments is 20 nanometers. In some embodiments, the conductivelayer 224 is deposited on the sidewalls of the second substrate 206 witha depth in a range of 2500 to 3500 nanometers, and in some embodimentsthe depth is 3000 nanometers.

In the illustrated embodiment, the sidewalls 220 of the plurality of viaholes 216 etched into the second dielectric layer 208 and the secondsubstrate 206 are perpendicular to the exposed surface of the firstdielectric layer 204. This profile obtained under ideal etchingconditions with idea sidewalls passivation in the device 300 is forillustration purposes and not intend to be limiting. Practical etchingconditions (i.e., etching rate in different directions) can causeeffects such as tapering, undercutting, notching, bowing, rippling,etc., which alter the sidewall profile of the openings 216. It should benoted that different sidewall profiles that can be obtained frompractical etching conditions are all within the scope of this invention.

FIG. 4 illustrates various sidewall profiles 400 of a via hole etched inthe second dielectric layer 208 and the second substrate 206, inaccordance with some embodiments of the present disclosure. The varioussidewall profiles 400 comprises a first profile 402 with verticalsidewalls 220 from an ideal etching condition, a second profile 404 withtapered sidewalls 220 and complete undercuts 416 under the seconddielectric layer 208 caused by a strong sidewall passivation, a thirdprofile 406 with tapered sidewalls 220 and partial undercuts 416 underthe second dielectric layer 208 caused by a spontaneous etchingreaction, a fourth profile 408 with sidewalls 220 comprising ripples418, a fifth profile 410 with smoothly curved sidewalls 220, a sixthprofile 412 with tapered sidewalls 220 and notches 420 at the bottom ofthe via hole caused by distorted ion trajectories and/or chemicaletching, a seventh profile 414 with inverted tapering sidewalls 220, andan eighth profile 416 with tapered sidewalls 220 and eroded corners 422in the second dielectric layer 206. It should be noted that sidewallprofiles in the FIG. 4 is for illustration purposes and not intended tobe limiting. Different sidewall profiles that can be obtained fromvarious etching conditions are all within the scope of this invention.

Referring back to FIG. 3 again, in the illustrated embodiment, theconductive layer 224 has a Q-tip cross-sectional profile, wherein theQ-tip cross-sectional profile is caused by directionality of thetechnique used for the deposition of the conductive layer 224. Forexample, as illustrated in FIG. 3 , a first width 318 between twoadjacent surfaces of the conductive layer 224 is smaller than a secondwidth 320 between the two adjacent surfaces of the conductive layer 224.For example, a sputtering deposition is directional causing a primarydeposition on surfaces that are facing the direction of the ion fluxfrom a sputtering target. For another example, for techniques that aredirectional, the conductive layer 224 can be only deposited on top ofthe second dielectric layer 206 with negligible deposition on thesidewalls 220 of the via holes 216. For another example, an evaporationdeposition is relatively less directional compared to the sputteringdeposition process, which results in a more uniform deposition of theconductive layer 224 on the sidewalls 220 of the via holes 216.Different profiles of the conductive layer 224 on the top surface anddifferent profiles of the sidewalls 220 of the via holes 216 can becombined and used, which are within the scope of this invention.

FIG. 5A illustrates an exemplary top view of a semiconductor device 500with a collimator structure, in accordance with some embodiments of thepresent disclosure. The collimator structure in the device 500 comprises81 via holes 216. In the illustrated embodiments, the via holes 216 eachhas a circular cross section. In some other embodiments, differentshapes (e.g., square) of cross sections of the via holes 216 can be usedand are within the scope of this invention. In the illustratedembodiments, the via holes 216 are arranged in a 9×9 array with a squareunit cell 502. It should be noted the device 500 in FIG. 5A is forillustration purposes, any numbers of via holes 216 can be used and iswithin the scope of this invention.

FIG. 5B illustrates an exemplary top view of a semiconductor device 500with a collimator structure, in accordance with some embodiments of thepresent disclosure. The collimator structure in the device 500 comprises77 via holes 216. In the illustrated embodiments, the via holes 216 eachhas a circular cross section. In some other embodiments, differentshapes (e.g., square) of cross sections of the via holes 216 can be usedand are within the scope of this invention. In the illustratedembodiments, the via holes 216 are arranged in an array with a diamondunit cell 504. It should be noted the device 500 in FIG. 5A is forillustration purposes, any numbers of via holes 216 can be used and iswithin the scope of this invention.

In one embodiment, an optical collimator, includes: a dielectric layer;a substrate; a plurality of via holes; and a conductive layer, whereinthe dielectric layer is formed over the substrate, wherein the pluralityof via holes are configured as an array along a lateral direction of afirst surface of the dielectric layer, wherein each of the plurality ofvia holes extends through the dielectric layer and the substrate fromthe first surface of the dielectric layer to a second surface of thesubstrate in a vertical direction, and wherein the conductive layer isformed over at least one of the following: the first surface of thefirst dielectric layer and a portion of sidewalls of each of theplurality of via holes, and wherein the conductive layer is configuredso as to allow the optical collimator to filter light in a range ofwavelengths.

In another embodiment, semiconductor device, includes: at least oneoptical sensing element; and an optical collimator; wherein the opticalcollimator comprises: a first dielectric layer, a first substrate, aplurality of via holes, and a conductive layer, wherein the firstdielectric layer is formed over the first substrate, wherein theplurality of via holes are configured as an array along a lateraldirection of a first surface of the first dielectric layer, wherein eachof the plurality of via holes extends through the first dielectric layerand the first substrate from the first surface of the first dielectriclayer to a second surface of the first substrate in a verticaldirection, wherein the conductive layer is formed over at least one ofthe following: the first surface of the first dielectric layer and aportion of sidewalls of each of the plurality of via holes, and whereinthe conductive layer is formed so as to allow the optical collimator tofilter light in a range of wavelengths.

Yet, in another embodiment, a method for forming a semiconductor device,includes: forming a collimator structure on a first substrate with afirst dielectric layer, wherein the collimator structure comprises aplurality of via holes, wherein each of the plurality of via holesextends through a second dielectric layer and a second substrate from afirst surface of the second dielectric layer to a second surface of thesecond substrate in a vertical direction; and for Ening a conductivelayer over at least one of the following: the first surface of thesecond dielectric layer and a portion of sidewalls of each of theplurality of via holes of the collimator structure.

The foregoing outlines features of several embodiments so that thoseordinary skilled in the art may better understand the aspects of thepresent disclosure. Those skilled in the art should appreciate that theymay readily use the present disclosure as a basis for designing ormodifying other processes and structures for carrying out the samepurposes and/or achieving the same advantages of the embodimentsintroduced herein. Those skilled in the art should also realize thatsuch equivalent constructions do not depart from the spirit and scope ofthe present disclosure, and that they may make various changes,substitutions, and alterations herein without departing from the spiritand scope of the present disclosure.

As used herein, the term “approximately” means in the range of plus orminus 10% of the stated value.

What is claimed is:
 1. An optical collimator, comprising: a dielectriclayer; a substrate; a plurality of via holes; and a conductive layer,wherein the dielectric layer is formed over the substrate, wherein eachof the plurality of via holes extends through the dielectric layer andthe substrate in a vertical direction, wherein the conductive layer isformed over at least one of the following: the first surface of thefirst dielectric layer and a portion of sidewalls of each of theplurality of via holes, and wherein a first thickness of the dielectriclayer is approximately 1.0 micrometer and a second thickness of thesubstrate is approximately 6 micrometers.
 2. The optical collimator ofclaim 1, wherein the conductive layer comprises aluminum copper (AlCu)alloy.
 3. The optical collimator of claim 1, wherein the conductivelayer is formed over both the first surface of the first dielectriclayer and the portion of sidewalls of each of the plurality of viaholes, and wherein a first thickness of the conductive layer over thefirst surface of the first dielectric layer is approximately 20nanometers and a second thickness of the conductive layer over thesidewalls of each of the plurality of via holes is approximately 2nanometers.
 4. The collimator of claim 1, wherein the conductive layeris formed over the portion of sidewalls of each of the plurality of viaholes, and wherein a depth of the portion of sidewalls with theconductive layer is approximately 3,000 nanometers, wherein the firstdepth is measured from the first surface of the dielectric layer.
 5. Thecollimator of claim 1, wherein each of the plurality of via holes has adimension of approximately 0.05 micrometers.
 6. The collimator of claim1, wherein the substrate is a silicon substrate.
 7. The collimator ofclaim 1, wherein the conductive layer is configured so as to allow theoptical collimator to filter light in a range of wavelengths between 780and 1400 nanometers.
 8. A semiconductor device, comprising: at least oneoptical sensing element; and an optical collimator; wherein the opticalcollimator comprises: a first dielectric layer, a first substrate, aplurality of via holes, and a conductive layer, wherein the firstdielectric layer is formed over the first substrate, wherein each of theplurality of via holes extends through the first dielectric layer andthe first substrate, wherein the conductive layer is formed so as toallow the optical collimator to filter light in a range of wavelengths,wherein a first thickness of the dielectric layer is approximately 1.0micrometer and a second thickness of the substrate is approximately 6micrometers.
 9. The semiconductor device of claim 8, wherein the atleast one optical sensing element is formed in a second substrate,wherein the second substrate is further coated with a second dielectriclayer, and wherein the optical collimator is formed over the seconddielectric layer.
 10. The semiconductor device of claim 8, wherein theconductive layer comprises aluminum copper (AlCu) alloy.
 11. Thesemiconductor device of claim 8, wherein the conductive layer is formedover both the first surface of the first dielectric layer and a portionof sidewalls of each of the plurality of via holes, and wherein a firstthickness of the conductive layer over the first surface of the firstdielectric layer is approximately 20 nanometers and a second thicknessof the conductive layer over the sidewalls of each of the plurality ofvia holes is approximately 2 nanometers.
 12. The semiconductor device ofclaim 8, wherein the conductive layer is formed over a portion ofsidewalls of each of the plurality of via holes, and wherein a firstdepth of the portion of side walls with the conductive layer isapproximately 2 nanometers, wherein the first depth is measured from thefirst surface of the first dielectric layer.
 13. The semiconductordevice of claim 8, wherein each of the plurality of via holes has adimension of approximately 0.05 micrometers.
 14. The semiconductordevice of claim 8, wherein the first substrate is a silicon substrate.15. The semiconductor device of claim 8, wherein the range ofwavelengths is between 780 and 1400 nanometers.
 16. A method for forminga semiconductor device, comprising: forming a collimator structure on afirst substrate with a first dielectric layer, wherein the collimatorstructure comprises a plurality of via holes, wherein each of theplurality of via holes extends through the first dielectric layer andthe first substrate in a vertical direction; and forming a conductivelayer over at least one of the following: the first surface of the firstdielectric layer and a portion of sidewalls of each of the plurality ofvia holes of the collimator structure, wherein a first thickness of thefirst dielectric layer is approximately 1.0 micrometer and a secondthickness of the first substrate is approximately 6 micrometers.
 17. Themethod of claim 16, wherein the conductive layer comprises aluminumcopper (AlCu) alloy.
 18. The method of claim 16, wherein the conductivelayer is formed over both the first surface of the first dielectriclayer and the portion of sidewalls of each of the plurality of viaholes, and wherein a first thickness of the conductive layer over thefirst surface of the first dielectric layer is approximately 20nanometers and a second thickness of the conductive layer over theportion of sidewalls of each of the plurality of via holes isapproximately 2 nanometers.
 19. The method of claim 16, wherein theconductive layer is formed over the portion of sidewalls of each of theplurality of via holes, and wherein a first depth of the portion of sidewalls with the conductive layer is approximately 3000 nanometers,wherein the first depth is measured from the first surface of the firstdielectric layer.
 20. The method of claim 16, wherein each of theplurality of via holes has a dimension of approximately 0.05micrometers.